Method of making interlocking roofing tile



June 18, 1940. D. BROWN ET AL METHUD OF MAKING INTERLOCKING ROOFING TILE2 Sheets-Sheet 1 June 18, 1940. D. BROWN Er A1. 2,205,080

METHOD OF MAKING INTERLOCKING ROOFING TILE Original Filedl Aug. 4, 19562 Sheets-Sheet 2 UNITED STATES y I '12,205,080y i METHOD orv MAKINGmTEnLocmG f nooFINdTim; naviserown and Joseph B. Peebles, Los Angeles,

and Bruner Moore Burchiiel, Glendale, Calif.;

said Peebles and said Burchliel assignors to said Brown 'i f Originalapplication August l4, 1936, Serial No. 94,184. -Divided and thisapplication January- 31, 1938, Serial No. v187,902.

3 claims. v(ci. 2s-15'6i This application is a division of our patenttion at one edge there is a partial rib, this being application forInterlocking roofing tile and about half the depth of the other ribs. Onthe method and apparatus for making, Ser. No, other margin a channel isformed facing up- 94,l84, led August 4, 1936, matured to Patent wardlyand this has a longitudinal rim on its 5 No. 2,177,607, issued October24, 1939. As it is outerv edge, such rim terminating in a. plane 5necessary to describe certain parts of the maof the underside of themain body of the rib. chine or equipment in relation to the method of Afurther feature in the method of making the making the tile and the tileas an article, we tile is passing this ribbon through an automatic usesome of the drawings of the parent applircutting machine which has atravelling carriage,

l0 cation -such carriage moving with the same speed as the l0 Ourinvention relates to a method of making ribbon after a predeterminedamount of such rooiing tile having a longitudinal edge interlockribbonhas been fed on to the carriage and then ing between adjacent tile, suchinterlock being the cutting of the ribbon to form both ends of of a typein which the drainage or seepage of the tile and the sealed end is donein one operwater at the longitudinal tile joints is carried ation, thisoperation also cutting oli a short 15 downward in part of theinterlocking construcwaste strip. The cutting is done during a lontionand thus drains' on to the lower tiles of a gitudinal motion ofthecutters and the press for roof. Another feature of our invention is insealing the end so that the longitudinal speed providing a sealed endclosure for a tile with of these cutters equals the longitudinal Speed0f ribs on its underside, such closure thus when the ribbon of clay.Thus, in the action of cut- 20 interfitted by an overlapwith other tilespreting the ribbon into tile lengths, a notch is cut vents seepage ofwater upward in the grooves out of one corner at the end of theinterlocking formed between the ribs on the underside of the channel,the lower end of each tile is sealed `or tile and also permits a lesseroverlap of the tiles. rounded oiI, this also forming a short wasteAnother feature involving the sealed end and Strip, the Opposite end iSCut by a Shear Gilt tranS- 25 the interlocking channel of adjacent tilesis in verse to the clay ribbon and at the Same time having the channelterminate slightly short of nail holes are punched adjacent the upperedge 0f the sealed end so that an adjacent tile has its the tile sealedend extend over and below the end of the Oui invention iS illustrated inconnection `with channel used for interlocking the adjacent tile. theaccompanying drawings, in which: 30

A characteristic therefore of our invention, is Fig. 1 iS a plan 0f aDOTtOn Of the machine that each individual tile has a series oflongishowing the Dart O the Carriage taken in the tudinal ribs on itsunderside thus forming direCtiOn 0f the aIrOW 0f Fig- 2I emitting hOW-grooves between the ribs. At the margin or ever, the hydraulic Operatingmechanism.

longitudinal side of each tile a longitudinal chan- Fig. 2 iS a Verticallngitlldinal Section 0n the 35 nel is formed and the edge of theadjacent tile line 2--2 of Fig. 1 taken in the direction of the has adownturned partial rib which interts with arrows showing part of theOscillating hydraulic the said channel. In addition the lower end ofmotor in elevation and a portion of the cutters each tile is roundedover forming a seal across and dies for forming the shingle, these beingin the ribs. This gives a convex curve to the lower an elevatedposition. 40 end of eachtile considered on a longitudinal scc- Fig. 3 isa partial longitudinal section similar tion and thus forms with the ribsflat underto Fig. 2 but showingthe cutters and dies in surface portionsto t on the nat top of an under their lowermost position when severingand dietile.v 'I'he sealed lower end of each tile where pressing theshingle end.

it is turned downwardly engages over the end of Fig. 4 isa perspectiveView of one of the tiles 45 the marginal channel of the adjacent tile,such showing the upper surface and the channel at channel being slightlyshorter than the total one side.

length of the tile. Fig. 5 is a perspective reverse view of the tile i Afurther object and feature of our invention showing the full ribs, thehalf rib on one edge is in the ymethod 0f manufacturing tile in a conandthe underside of the channel. 50 tinuous and in effect, automaticmanner. In Fig. 6 is a plan of an assembly of tiles in a this a ribbonofclay is forced through a suitable y roofing. extruding machinewhichforms the ribbon with Fig. 7 is a transverse section of twoadjacent continuous longitudinal ribs onv its underside, tiles ontheline .'l-l of Fig. 6 in the direction these ribs being all of thesame depth. In addiof the arrows. 55

Our invention as it relates to the tile is illustrated particularly inFigs. 4 through 7 in which the individual tile is indicated by thenumeral II. This is formed from a continuously molded ribbon of claywhich has a web I2 with a series oi internal ribs I3 formed on the lowerside. The formation of the ribs thus forms wide longitudinal grooves I4.At one marginal edge a partial and designated half rib or rim I5 isformed, there being a narrow groove I6 between such marginal half rib orrim and the next adjacent full rib I3. It will thus be seen that theupper surface of the ribbon presents a smooth surface of the web of thetile except that on one margin there is formed a longitudinal channelI1, this being on the side opposite that having the half rib or rim I5.This channel has a marginal half rib or rim I8. The base or underside I9 of the channel is on the same plane as the bottom edge 20 of the mainribs I3 so that the half rim or rib I8 is approximately the same invertical measurement as the half rib or rim I5 on the opposite side ofthe ribbon. The inner face 2| of the channel I1 is thus in effect ap0rtion of the side face of a rib. It will be understood that as theribbon of clay is extruded ina continuous operation that the web, thevarious interior ribs, the marginal rim I5 on one side and the channelstructure I1 on the opposite side are formed in a continuous manner andthat the individual tiles are made by cutting into proper lengths. Inthis cutting a transverse cut is made which forms the upper end 25 of anindividual tile, this serving the web, the various internal ribs, themarginal rim I5 and the channel structure I1. This cut is at rightangles to the plane of the ribbon. 'I'he lower end of the tile is formedwith a sealed end 26. This is made by die-pressing the web portiondownwardly forming connected cross blocks 21 between the ribs and alsopartially widening or spreading the ends of the ribs I3 adjacent theirlower end as indicated at 28. The characteristic of the sealed end 26 isthat it has a convex rounded curvature 29 merging with the top surfaceof the web I2 and this convex curve or nose merges into a sloping endedge 30 which forms an obtuse angle with the plane of the web of thetile. The sealed end has a transverse under'edge 3| which is in the sameplane as the bottom I9 of the channel and of the lower edges 20 of themain ribs I3.

In the same operation in which the sealed end is die-pressed in shape, anotch 35 is formed at the lower end of the channel structure I1.v 'I'hisis done by making a transverse cut which severs the half rib or rim I8of the channel, the bottom of the channel leaving an end face 36. 'I'hisaction also makes an end cut 31 in a portion of the lateral rib 38.There is also a longitudinal cut 39 made in this rib from the sealed end26. This leaves a right angular corner 40 at the transverse cut of thechannel I1 at its end face 36 and the side face 39 cut in the rib 38.

To intert with this the rim I5 joins with the sealed end 26 on ajunction line 4I which is positioned slightly above the lower edge 3i ofthe sealed end as shown in Fig. 5. It will be noted that in forming theribs, the center ribs I3 have a small llet 42 where they join the webI2. 'Ihc rib 38 adjacent the channel I1 has a larger fillet or slopingside wall 43.` Also the rib 44 which is adjacent the groove I6 also hasa large fillet 45 or sloping inner edge. This construction at the ribs38 and 44 strengthens the connection of the channel structure I1 on oneside of the tile and the groove structure I6 with the rim I6 on theopposite side of the tile.

'I'he tiles are provided with the usual nail hole perforations 46 spacedinwardly from the edge 25. In this construction of a sealed tilehowever, the nail holes may be made much closer to the upper end of thetile than in the usual tile as it is not necessary to have such anoverlap of the tiles when laid up on a roof.

In setting up the tiles they interflt as shown in Fig. 7 in which itwill be seen that the rim I6 on one side oi' a tile fits in the channelI1 on the edge portion of an adjacent tile. It will be noted that therim I8 on the outside of the channel I1, being of half the rib height,substantially engages the underside of the web I2 whereas the edge ofthe rim I5 substantially engages the bottom of the channel I1. Theoutside of the rim I5 is in close engagement with the longitudinal edgesurface 2| of the channel I1 and the rim I8 is in close engagement withthe rib 44 of an adjacent tile.

The corner portion of the sealed end 26 of the tile at its junction withthe rib I5 fits in the notch 35 formed by cutting the channel I1 ashorter length than the main body of the tile so this gives a sealacross the end of the channel I1. Therefore any water seeping betweenadjacent tiles and ilowing down this channel is directed downwardly ontothe tiles immediately below in a roof structure.

Our invention, so far as the machine assembly is concerned, has thefollowing main features in which an extruding machine extrudes through adie forming a ribbon of clay 52. This is received by a transfer table 53mounted on a substantial frame structure 54. This frame structure formsa mounting and track for the carriage designated by the assembly numeral55. The carriage is mounted on wheels in the usual manner to facilitateits reciprocating movement. The shingles after being formed are conveyedfrom the machine by an out-feeding conveyor, this travelling at a higherrate of speed than the ribbon of clay to lead the cut tiles quickly awayfrom the machine.

Certain characteristics of the carriage 55 is that this has a carriagebed 51 with marginal guides 68 and 59 (note Fig. 1), these being formedof angle-irons and between such angle-irons there are longitudinalstraps 60 which fit the grooves between the main rib. 'Ihere is also aside strap 6I with a longitudinal recessed edge 62 which accommodatesthe marginal rim I5. These straps and the angles have a somewhat pointedend 63 to facilitate feeding the ribbon of clay over these straps. 'Ihestraps have a slightly beveled end 64 remote from the end 63. Themachine is provided with a cutting and die-pressing assembly 65. Thishas an upper frame 66 supported on four vertically reciprocating rods61, these being connected to longitudinal angles 66 forming part of thetop frame 66, this frame being adjustable on these rods. 'I'he rods passdownwardly through tubular guides 69 forming part of the carriage bed orsecured thereto in any suitable manner. The lower ends of these rods areconnected to a lower frame 10. This frame has longitudinal angles 1I andcross or transverse angles 12. l

The cutters include a transverse severing blade 15 which is illustratedas secured to a transverse angle-iron 16 extending between thelongitudinal angles 68 of the top frame 66 and is adjustablelongitudinally to regulate the length of the tile. Punches 11 are alsosecured to the angle-iron 16 to punch the nail holes.

The die 80 for forming the sealed end on the .tile has a sloping blade8| depending from a cross strap 82 located between the longitudinalangles 68. This blade slopes at an angle upwardly and towards thesevering blade and forms the main portion of the end seal 26, giving theslope to the end 30 and bythe downward ilow of clay I adjacent the topsurface of the web forms the convex curve 29. This die has alongitudinally extending blade section 82 and an outwardly extendingshearing blade 83 which forms the notch 35. 'I'he longitudinal shearingpart 82' cuts the longitudinal cut-39 of the notch and the .out-

wardly extending shearing blade 83 gives the transverse cut 36v and 31atvthe Vend of the channel structure I1. Forming the notch causes a slightwaste inthe clay ribbon forming the tile.

The cutter assembly with the blade and the end seal forming die isvertically reciprocated by an oscillating engine 85. This engine has acrank shaft 86 extending therethrough with a crank 81 on each end. Fromeach crank there depends a connecting rod 88 which is pivotallyconnected at 89 to a cross or transverse angle 12 which angles form ineffect a cross head. The engine has two similar end heads 98 which havea supporting base 9| bolted to a cross channel 92 which forms part ofthe machine carriage. Between thesev heads there is a ring 93cylindrical on-its inside surface, this ring fitting against shouldersof the end heads and the assembly being attached by bolts.

The two supply pipes have elbows |22 and there are two longitudinalpipes |23 and |24 (note Fig. 2) which are supported in the carriage andfrom'each of these there is a ilexible hose leading to couplings of acontrol valve. This valve may be of the usual character and has an inletconnection from a hydraulic pump and return to the pump or a reservoir,thus by a suitable control of the oscillating engine 85 as described inthe parent application above noted, such engine is operated to oscillatethe shaft 86 and hence raise and lower the cutting and die pressingassembly 65.

The mechanism for' initiating the movement of the carriage with theribbon of clay and the return of the carriage at the end Aofits strokemay be arranged somewhat in the manner of the patent application toDavis Brown for Automatic brick and tile cutter, Ser. No. 44,727, lledOctober 12, 1935, matured to Patent No. 2,058,663, issued October 27,1936.

In this cutting action the transverse cutter blade l5 isbrought down atpredetermined periods during which time a ribbon of clay has been fed,thus giving a series of cuts, two of which are indicated at |85 in Fig.3. At the same time the diecutter makes a severance cut |86 as v well asdie-pressing the end of the tile. Thus riage.

-and 31.

The cuttingv edge of this sloping blade is horizontal and thus parallelto' the bed of the car- However the sloping part of this blade does notextend the full width of the clay ribbon from which the tile'is formedand cut but at the left hand end considered facing in a forwarddirection of the movement of the ribbon, there is a -longitudinallyextending blade section 82 which is vertical as clearly shown in Fig. 2.At thel rear end of this latter blade lthere is the shearing blade 83which is also vertical as shown in Figs. 1 and 2.v Thus in the operationas shown in connection with Fig. 3, the shearing blade 15 cuts throughthe ribbon of clay, making a ver- -tical cut and. completely severingthe' web and the various ribs. The action of .the die and in particularthe sloping blade 8| in its downward movement engages the ribbon back ofthe right 'The characteristics of the action of the longitudinal blade82' and the cross blade 83 is at the same time to form a longitudinalcut in the clay forming the surface 39 shown in Fig. 4

and to make the cut crosswise at the right angular corner 40, leaving.exposed the surfaces 36 This cutsout the notch designated as 35, Fig. 4.In this action the cutting edges at the bottom of the die, that is, thecutting edge of the sloping blade 8| and of the blades 82' and 83, areall on the same level and thus cut through the web, the ribs and thechannel structure giving the formation at the end of the tile shown inFigs. 4 and 5 and developing a slight waste strip |81 which includes theportion cut out to form the notch 35.

Various changes may be made in the details 4of the construction withoutdeparting from the an upper surface for exposure to the weather and apluralityA of downwardly extending ribs with spaces between the ribs andthe web comprising while the ribbon is moving in a forwarddirection atthe rate of extrusion, in asingle operation severing the ribbon to forma tile length and at the same time deforming one end of the web and aportion of the ribs adjacent thereto to formv an end seal integral withthe web and the ribs and bringing the lower edge of the seal intoalignment with the lower edge of the ribs whereby the said seal forms anend closure for the space between the ribs and the web when the tile isset up on a roof.

2. In the method of making roong tile as claimed in claim 1, at the sametime of severing the ribbon into a tile length forming a waste piecesupporting the web with a moving support on the underside between theribs except at the end which is deformed and in the deforming of the endof the ribbon and ribs pressing the under portion of the web and theside portions of the ribs into contact with the moving support.

3. The method of making rooiing tile in which a ribbon of clay iscontinuously extruded to form a web with an upper surface for exposureto the weather and a plurality of ribs iormed integral 75 10 the saidseal forms an end closure for the said space when the tile is set up ona roof, supporting the web of the portion of the ribbon to be severedinto a tile during its movement except at the end in which the seal isformed whereby a portion of the web is distorted downwardly and the endportion of the ribs distorted laterally to form the end seal.

DAVIS BROWN.

JOSEPH B. PEEBLES. BRUNER MOORE BURCHFIEL.

